FDC Construction and Fitout has delivered the $130 million Truganina National Distribution Centre (TNDC) for Mondelēz International in Melbourne’s western suburbs.
The 47,000-square-metre facility is the company’s largest in-house automated warehouse in the world and will support the distribution of Australian-made Cadbury Dairy Milk products, along with snacks from The Natural Confectionery Company, Olina’s Bakehouse and OB Finest.
Championing automation, efficiency and sustainability, the site’s design includes an integrated automated storage and retrieval system by Swisslog, with planning for the system incorporated early in the concept design phase. FDC worked closely with architects to map out the structural and spatial requirements ahead of development approval.
To accommodate the 32-metre-high ASRS system within the 11,550-square-metre high bay area, the project team adjusted the construction methodology. Unlike typical warehouse builds, the high bay slab was poured before the erection of structural steel and cladding. This approach allowed for a faster and safer steel installation from a completed surface, and was supported by additional curing time, protection measures and inspection protocols.
Mechanical plant and roof-mounted equipment were installed via helicopter lift, reducing the need for large cranes and supporting an accelerated schedule to meet early access requirements for automation contractors.
Coordination across all project partners, including Mondelēz and Swisslog, was essential to safely deliver the complex build. The slab installation provided a stable platform for the subsequent installation of ASRS components and helped mitigate working-at-height risks.
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The completed facility features 28 recessed docks, 12 on-grade docks, a 25-metre super canopy, a 5,000-square-metre low bay expansion area, and supports up to 150 vehicle movements per day. It is partly powered by a 1-megawatt solar system.
FDC collaborated with Sustainable Development Consultants and an independent commissioning agent throughout the project to meet Mondelēz’s sustainability targets. During construction, 90 per cent of waste was diverted from landfill, and 30 per cent of the build was powered by solar energy. The facility will operate on 100 per cent renewable electricity and achieved a sustainability impact score of 92 per cent.
Cameron Jackson, general manager for Victoria at FDC, said the facility would support Mondelēz’s operations for years to come.
“As businesses look to future-proof their distribution network to meet growing consumer demands, especially in Victoria, FDC remains a trusted partner in delivering industry-leading warehouse facilities,” said Jackson.
“This project demanded our blend of technical expertise and innovative construction techniques. From early concept design to completion, FDC ensured we met the exacting storage compliance and climate-controlled needs of a confectionery storage facility…injecting creativity [into] how we manoeuvred complex, large-scale elements.
“Managing the helicopter installation of the mechanical plant and associated roof-mounted equipment was undoubtedly a significant highlight for our team.”
Wayne Angus, vice president of supply chain for Australia, New Zealand and Japan at Mondelēz International, said the centre reflects the company’s ongoing investment in local manufacturing.
“Our need was a technologically advanced, high-volume facility, and we required a team that could be agile, innovative and collaborative in their delivery of this project,” said Angus. “FDC was a trusted partner who brought creative solutions and a high level of expertise and teamwork to all aspects of this build.”